Project Report

On

TWO-WHEEL FORKLIFT MACHINE

Submitted in partial fulfilment for the award of degree of

BACHELOR OF TECNOLOGY
In
MECHANICAL ENGINEERING
at

GLOBAL INSTITUTE OF TECHNOLOGY, JAIPUR

SUBMITTED TO SUBMITTED BY
Mr. Ghanshyam Mishra Anurag Meena (17EGJME003)
(Mechanical Department) Krishnam Kushwaha (17EGJME021)
Rajesh Janyani(17EGJME042)
Rohit Sen(17EGJME045)

DEPARTMENT OF MECHANICAL ENGINEERING

GLOBAL INSTITUTE OF TECHNOLOGY, JAIPUR
(RAJASTHAN)-302022
2-Wheel Forklift GIT DME

CERTIFICATE
This is to certify that the project work report entitled “TWO-WHEEL FORKLIFT MACHINE”
submitted to the Department of Mechanical Engineering, Global Institute of Technology, in
partial fulfilment for the award of degree of Bachelor of Technology in Mechanical
Engineering, is a record of beanfield work and an authentic record of our own work carried out
by all the group members under the supervision of Mr. Ghanshyam Mishra, Department of
Mechanical Engineering

The matter presented in this project has not been submitted by me anywhere for the award of
any other degree or to any other institute.

Signature: -

Anurag Meena

Krishnam Kushwaha

Rajesh Janyani

Rohit Sen

This is to certify that the above statement made by the candidate is correct to best of my
knowledge.

Guide: -

Mr. Ghanshyam Mishra

Head of Department

Department of Mechanical Engineering

Global Institute of Technology, Jaipur

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ACKNOWLEDGEMENT
All of us know that the project work is not a single man’s job & without the support of others
it is rather impossible to complete the work. The completion of this project would not have
been possible without the expert guidance and support of our respected project guide and the
Head of our department for his continuous support and also valuable suggestions when required
by our respected Professors at the college.

We would be leaving a great dent in the work if we don’t thank the following persons. We are
very much thankful to,

First & foremost, we express our gratitude to our project guide Mr. Ghanshyam Mishra for
his valuable guidance and support for work and also the encouragement to make the project
successful.

We would also thank Global Institute of Technology, Jaipur to provide us with resources and
infrastructure to fabricate and present our project.

At last, but not the least I am also thankful to my team members for their effort, participation,
enthusiasm, helping to build and bring out great team work to bring success of the project.

We can’t forget the valuable support of our parents also, who have always stood by us, with
their constant and encouragement throughout the project work.

Anurag Meena (17EGJME003)

Krishnam Kushwaha (17EGJME021)

Rajesh Janyani (17EGJME042)

Rohit Sen (17EGJME045)

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ABSTRACT
Forklifts are used to move large and heavy loads; the size is adjustable to adapt to loads of
different sizes and to seal warehouse conveyors. The adjustable width allows the conveyor to
replace relatively thin passages. A high degree of manoeuvrability is achieved through the use
of steering drive wheels; the lifting of the load is carried out by the mechanism of self-propelled
mechanical equipment located on both sides of the conveyor. Conveyor operation is controlled
by a manual control unit. An elongated vertical element mounted on a mounting element
movably mounted on a truck frame and at least one loading device, the loading device having
at least one loading part and two mounting parts, the mounting part can pass through the
corresponding vertical element Insert into the opening in the centre, and fasten the ele ments
such as pins or bolts passing through the alignment holes through the vertical members and the
fastening parts to fix the fastening elements in place, and the fasteners are spaced between the
corresponding vertical elements. This can also be achieved by a combination of fork tips. Each
fork tip has a loading port and a fastening part, which can be inserted into the upper or lower
end of the opening of various vertical supports, or a tool extender, the loading part of which is
suitable. The container interacts, its fastening material can be inserted into the upper open end
of the vertical element and activate a 180-degree movement.

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SELECTION OF THE PROJECT

Selection of project is an important aspect of this course. Project must be appealing in learning
aspects and should provide a scope of developing the qualities – technical and managerial
both. The group had a thorough discussion and analysis of various ideas.

This discussion included talks on new trends in the fields, learning aspects provided by them,
cost consideration, SWOT analysis of them, weightage of work provided to have inclusive
participation and many other factors.

After the discussion and literature study the team had come down to a shortlist of few ideas
that would serve the purpose to its whole content. The projects considered were

• Solar Operated Bicycle

• Wind Operated Bicycle
• Two Wheel Forklift
• Electricity Generation by Speed Beaker
• Multi Hacksaw Cutter
• Mechanical Segway

The team after discussion on certain factors came to the selection of Two Wheel Forklift.
This decision was an inclusive one where all the team members brought in their views of
advantages and backdrops. The discussion helped to develop the quality of considering factor,
evaluation, and also to bring out ideas and also how to conduct them.

The team selected The Project of Two Wheel Forklift because of these aspects:

• The Forklift Project includes a well enough use of manufacturing processes and thus will
develop a practical knowledge of carrying them out and apparatus used.
• The project has good scope of testing the skill and knowledge of estimating and costing.
• The project has a various part that would be required to purchase thus exposing us to
market survey and develop skill of compare and purchase.
• There is a wide scope of Two Wheel Forklift in every Industry where Material Handling
is required.
• Without the forklifts no warehouse industry will work efficiently.

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• Two Wheel Forklift uses hydraulic principle for lifting Heavy loads so there is no fuel
required hence no environment pollution will occur.

• Forklifts are very compact in size and can be used in very small passages so material
handling can be carried out success fully for indoor uses.

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PROJECT PLANNING
Before starting any project, its planning is to be done. Planning of project is a very important
task and should be taken up with great care as the effective implementation of the whole project
largely depends upon unit planning.

Project planning consisted of following steps:

• Selection of project
• Production Capacity
• Investment Decision
• Design and Drawings
• Selection of Material
• Selection of Machine tools and equipment required.
• Resource labor, transportation and loss in manufacturing.
• Inventory planning
• Process planning
• Preparation of F.P.C and O.P.C
• Costing and Estimating
• Testing of project
• Market response of project

Project planning is thus helpful to totally prepare an action plan that would lead to success of
the project. As it is said “A work well begun is half done.” The same sense is applied here “A
project well planned is half done.”

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CERTIFICATE ................................................................................................................... i

ACKNOWLEDGEMENT .................................................................................................. ii

ABSTRACT...................................................................................................................... iii

SELECTION OF THE PROJECT ...................................................................................... iv

PROJECT PLANNING ..................................................................................................... vi

LIST OF CONTENT…………………………………………………………………………vii

LIST OF FIGURES…………………………………………………………………………. ix

LIST OF TABLES………………………………………………………………………….…x

CHAPTER 1 INTRODUCTION ...................................................................................... 1

1.1 HISTORY OF FORKLIFT ..................................................................... 2

CHAPTER 2 WHAT IS FORKLIFT ............................................................................... 4

2.1 LITERATUR REVIEW STUDIES ......................................................... 4

2.2 WORK ACTIVITES .............................................................................. 5
2.3 CAPACITY ........................................................................................... 6
2.4 HEIGHT ................................................................................................ 6
2.5 FORKLIFT AWARENESS .................................................................... 6
2.6 CLASSIFICATIONS………………………………………………………7

CHAPTER 3 TWO-WHEEL FORKLIFT MACHINE ................................................. 11

3.1 OBJECTIVE OF THE PROJECT ......................................................... 11

3.2 PROBLEM STATEMENT ................................................................... 11
3.3 METHODOLOGY............................................................................... 12
3.4 DESIGN OF EQUIPMENT AND DRAWING ...................................... 12
3.5 SCOPE OF THE PROJECT.................................................................. 13
3.6 MARKET SURVEY ............................................................................ 14

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CHAPTER 4 WORKING PRINCIPLES ...................................................................... 15

4.1 THREE MAJOR PRINCIPLES ............................................................ 15

CHAPTER 5 RESEARCH AND EXPERIMENTAL WORK DONE ........................... 17

5.1 COMPONENTS USED ........................................................................ 17
5.2 PHYSICAL PARAMETERS OF ALL THE COMPONENTS USED..... 25

CHAPTER 6 DESIGN AND CALCULATIONS ........................................................... 26

6.1 DESIGN OF LEAD SCREW................................................................ 26
6.2 DESIGN OF NUT................................................................................ 30
6.3 REVOLVING SPEED OD SCREW...................................................... 30
6.4 SELECTION OF MOTOR ................................................................... 31
6.5 SELECTION GEAR ............................................................................ 32
6.6 SELECTION BATTERY ..................................................................... 34
6.7 SLEECTION OF BEARING ................................................................ 35
6.8 DESIGN OF FORK.............................................................................. 36

CHAPTER 7 EQUIPMENT AND OPERATIONS USED FOR FABRICATION......... 37

7.1 REQUIRED EQUIPMENTS REQUIRED MACHINE TOOL ............... 37
7.2 REQUIRED TOOLS ............................................................................ 37
7.3 REQUIRED MEASURING INSTRUMENTS....................................... 37
7.4 OPERATION PERFORMED DURING FABRICATIONS.................... 37

CHAPTER 8 COST ESTIMATION............................................................................... 39

CHAPTER 9 ADVANTAGES, DISADVANTAGES AND APPLICATIONS ............... 41

9.1 ADVANTAGES .................................................................................. 41
9.2 DISADVANTAGES ............................................................................ 41
9.3 APPLICATIONS ................................................................................. 41

CHAPTER 10 RESULTS AND DISCUSSIONS ............................................................ 43

CHAPTER 11 CONCLUSION AND FUTURE SCOPE ................................................ 44

REFERENCES ............................................................................................................... 45

RESEARCH PAPER………………………………………………………………………..46

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LIST OF FIGURES

Figure Name Pag e No.

2.1 Three- or Four-Wheel Forklift Truck 7

2.2 Reach Trucks/ Narrow-Aisle Forklift 8

2.3 Order-Pickers/ Stock-Pickers 8

2.4 Turret Trucks Type Forklift 9

2.5 Rough Terrain Forklifts 9

2.6 Hydraulic Fork Lift or Pallet Truck 10

2.7 Side Loader Forklift 10

3.1 Diagram of Two-Wheel Forklift Machine 13

4.1 Three Point on Contact Frame 16

5.1 DC Motor 18

5.2 Gear 18

5.3 Battery 19

5.5 Nylon Caster Wheels 21

5.6 Supporting Wheels 21

5.7 Lead Screw 22

5.8 Bearing 24

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LIST OF TABLES

Table No. Page N o.

1 Properties of Square Thread 27

2 Specification of Motor 31

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CHAPTER 1

INTRODUCTION
The forklift can be defined as a tool capable of lifting hundreds of kilograms. A forklift is a
vehicle similar to a small truck that has two metal forks on the front used to lift cargo. The
forklift operator drives the forklift forward until the forks push under the cargo, and can then
lift the cargo several feet in the air by operating the forks. The forks, also known as blades or
tines, are usually made out of steel and can lift up to a few tons.

Forklifts are either powered by gasoline, propane, or electricity. Electric forklifts relay on
batteries to operate. Gasoline or propane forklifts are sometimes stronger or faster than electric
forklifts, but they are more difficult to maintain, and fuel can be costly. Electric forklifts are
great for warehouse use because they do not give off noxious fumes like gas powered machines
do.

Forklifts are most often used in warehouses, but some are meant to be used outdoors. The vast
majority of rough terrain forklifts operate on gasoline, but some use diesel or natural gas.
Rough terrain forklifts have the highest lifting capacity of all forklifts and heavy-duty tires (like
those found on trucks), making it possible to drive them on uneven surfaces outdoors.

It is important for forklift operators to follow all safety precautions when using a forklift.
Drivers should be careful not to exceed the forklift's weight capacity. Forklift operators also
need to be able to handle forklift's rear wheel steering. Driving a forklift is similar to driving a
car in reverse, meaning that the driver must constantly steer to keep it moving in a straight line.
The driver must be aware of the forklift's ever-changing centre of gravity and avoid making
any quick sharp turns or going too fast. It is advisable that anyone who operates a forklift be
fully trained and licensed.

Forklifts have revolutionized warehouse work. They made it possible for one person to move
thousands of pounds at once. Well-maintained and safely operated forklifts make lifting and
transporting cargo infinitely easier. This is the general description of a normal forklift truck.
To enhances the technology further, this prototype module is constructed with remote
technology, there by the operator can walk along with the forklift for better visibility& the

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container can be placed accurately (precision position). This increases the safety of the
operator.

The mechanical structure of this prototype module is constructed with square metal pipes, this
structure looks like a rectangular box & the vertical moving mechanism that contains metal
forks is assembled over the structure at front side.

The fundamental concept involved in the system is to create mechanical movements in the
forklift according to the command signals generated and transmitted through the buttons
situated on the handle of the forklift. Various configurations allow different movement of the
forklift.

To make the project work more realistic, much importance is given for practical orientation,
therefore a prototype module is constructed for the demonstration purpose. This module
simulates the real working system & based on this technology with slight changes in the
structure & motor ratings, the system can be converted for real applications. The method of
converting rotary to linear motion is implemented in the mechanism. The forklift is designed
to move in all directions including reverse direction also.

1.1 HISTORY OF FORKLIFT

Just like many other inventions, the forklift was born out of necessity. The two-wheel hand
operated forklift first appeared over one hundred years ago. These original units were wrought
iron axle and cast-iron wheels which enabled loads to be lifted and transported without manual
labor. In the early 1900s the evolution to combine horizontal and vertical motion resulted in
the first-hand operated forklift capable of lifting a few inches of the ground. And with this the
development of the forklift are on Fastrack till today. In 1917 the Clark Company,
manufacturers of axles, created a truck called the Tractator to move materials around their
factory. As people visited the factory and saw the Tractator at work they placed orders from
Clark to build Tructractors for their companies. A few years later the first hydraulic p owered
lift was added to some trucks to give them lifting power. In 1923, Yale was the first company
to use forks that lifted loads off the ground and an elevated mast that could extend beyond the
height of the truck. The Yale truck is considered to be the first forklift.

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A few developments helped the forklift to increase in production including the introduction of
the standardized pallet in 1930 and World War II. Both of these developments increased
production of forklifts and allowed distributors the means to efficiently move heavy loads.

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CHAPTER 2

WHAT IS FORKLIFT?

2.1 LITERATURE REVIEW STUDIES

2.1.1 BURINSKIENE: “THE TRAVELLING OF FORKLIFT IN WAREHOUSE”.

RETRIEVED 2008-01-22.

After conducting an intensive literature review, it was found that Extreme pressure is placed
on all functions of a traditional warehouse. The warehouses have to be flexible and can
increase or decrease their operations to meet any demand. This has both advantages and
challenges. A key advantage is that warehouses are ready to un derlay economic trends and
seasonality. A key challenge is that they have to stay competitive in today’s market. This
means that managers and engineers must continue to improve the performance of their
warehouse operations.

2.1.2 BRINDLEY, JAMES (DECEMBER 2005). "THE HISTORY OF THE FORK

LIFT".

Warehouse & Logistic News. Archived from the original on 2009-08-31. Retrieved 2008-01-
25. In 1906, the Pennsylvania Railroad introduced battery -powered platform trucks for
moving luggage at their Altoona, Pennsylvania train station. World War I saw the
development of different types of material handling equipment in the United Kingdom.

2.1.3 DR. R. N. MALL (2013), AUTOMATED GUIDED VEHICLE, ISBN 2091

JOURNAL, MMMEC, GORAKHPUR.

In the market there are several types of forklifts are used in warehouses. These forklifts are
either powered by gasoline, propane, or electricity but they are more difficult to maintain and
fuel can be costly which takes more space. To overcome this entire problem, we designed and
fabricate the wheel forklift which drives on electric power, and loading & unloading is done
by a hydraulic jack through forks.

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2.2 WORK ACTIVITIES

Forklift trucks are vehicles designed to move and stack heavy or bulky goods. They are mainly
used in warehouses, stockyards and other storage areas. Forklift trucks are highly mobile with
a very small turning circle which allows them to move easily in confined spaces. On the front
of the truck are two forks operated by hydraulics. The driver must fit these forks into the pallets
on which goods are stored. The operator then uses the hydraulic forks to lift the pallet, takes it
to where it is needed and sets it down.

Some goods, such as bricks, can be moved by fork-lift trucks without the need for pallets.
They are stacked in bales with spaces for the forks. The operator must work carefully as these
goods are not protected by pallets. Some trucks are fitted with small computer display panels
that direct the operator where to place goods in the warehouse.

Operators may also have to keep records and follow instructions written on a worksheet. They
are also responsible for the basic maintenance of the truck. This includes greasing or oiling
parts and changing or recharging the battery. Forklift truck operators may have to work in a
noisy and dusty environment. Working outdoors in all weather conditions may also be
necessary.

Industrial lift trucks are used for handling materials, parts, products, tools, equipment, supplies
and maintenance items. Forklifts are efficient for material hand ling because they are self-
propelled, manoeuvrable and require only one operator to lift, transport, and stack or un - stack
the material. Forklifts may be used for indoor or outdoor use depending on their size, tires and
load capacities. The major factors that lead to injuries involving the use of forklifts include
unsafe driving and material handling practices.

Although the term 'forklift', 'fork lift', or 'fork truck' is instantly recognizable, their full, official
title is a Fork Lift Truck, due to the fork shaped tool at the front that traditionally was used to
lift pallets. But now, like any other piece of equipment, the forklift has evolved and is available
in a wide variety of styles, with varying functions and capacities, depending on where and how
they are to be used.

All lift truck operators must be trained prior to operating a lift truck. Training is provided by
the concern manufacturer and consists of both formal instruction and practical training.
Training is both vehicle- and workplace-specific. The training is a one-time requirement unless

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the operator is involved in a lift truck accident or is observed operating the truck in an unsafe
manner.

Industrial lift trucks must be inspected prior to each day of service. A daily inspection checklist
must be completed and any defects should be reported and corrected immediately. A truck may
not be placed into service if any defects are found during the inspection.

2.3 CAPACITY

Usually, forklifts start at around 600 kg load lifting capacity and go up to 52,000 kg, which is
a staggering 52 tons. Most forklifts are rated for less than 3 tons. However, weight is not as
straightforward as it may seem. The size of the load will also impact th e capacity. Weight
capacity is usually based on a 600 mm (24 inch) load centre, although this can vary. This means
that the distance from the centre of the load the edges can be no more than 600 mm. If the load
is bigger and/or longer, the truck will not be able to lift as much weight.

2.4 HEIGHT

The height that forklifts trucks can lift to varies enormously. Some can lift up to 11 meters or
more (some 36 feet) whereas the basic ones will lift less than 3 meters (10 feet). Generally,
height requirements are fairly static; depending up on the requirement, lifting height can be
adjusted by the manufacturer.

2.5 FORKLIFT AWARENESS

In every wholesaler-distributor operation, stacks, bundles and rolls of raw material and finished
products of various shapes, sizes and weights must be moved. Excessive and inefficient
material handling affects the productivity and profits. And manual material handling may be
dangerous. Efficient material handling systems and safe operation of material handling
equipment such as powered industrial trucks are the solution.

A powered industrial truck is defined as a mobile, power-driven vehicle used to carry, push,
pull, lift, stack or tier material. Forklifts are one type of powered industrial truck used by many
wholesaler-distributors. Other powered industrial trucks are known as pallet trucks, rider
trucks, fork trucks, or lift trucks. There are many types and sizes of powered industrial trucks
designed for different jobs. Many are named by the function they perform, such as high lif t
trucks, counterbalanced trucks, rider trucks and forklift trucks. Powered industrial trucks refer

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to as forklifts are used throughout the wholesale distribution industry to move raw materials
and stock and to elevate personnel.

2.6 FORKLIFT CLASSIFICATIONS

There are seven classes of forklift that describe the fuel option of the forklift and the use.
Each forklift operator must be certified to use on each class of forklift that they will operate.

a) 3- OR 4-WHEEL FORKLIFT TRUCK

Three-wheel forklift trucks are used for indoor and warehouses where space requirement is
very important. While four-wheel forklift trucks are used for lifting heavy loads in outdoor
uses and transportation at long distances. Used for loading trucks and m oving pallets and
other loads. It may be electric, diesel or gasoline operated. Diesel and gasoline powered
forklifts will generate more power than electric lifts and move faster over long distances.
Capacity ranging from 3 ton- 40 ton.

FIG. 2.1: - Three- or Four-Wheel Forklift Truck

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b) REACH TRUCKS/ NARROW-AISLE FORKLIFT

Perfect for optimizing storage space use. Use to rack pallets on smooth surfaces. Are
generally electric powered. Very much useful at small passages in warehouses and small
industries. Can lift heights up to 10 meters. Ranging from 1-3 tons load lifting capacity.

FIG. 2.2: - Reach Trucks/ Narrow-Aisle Forklift

c) ORDER-PICKERS/ STOCK-PICKERS

Use for rider to stand on an elevating platform

along with forks so rider may rise to select the
materials. Very much useful for packaging
industries and warehouses where they are
constantly required to pick and put heavy
packages at certain level. Used in very narrow
paths. Generally electric powered. Capacity
ranging from 1-3 ton.

Fig. 2.3: - Order-Pickers/ Stock-Pickers

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d) TURRET TRUCKS TYPE FORKLIFT

In this type of forklift, Forks are mounted on a mast and carriage that operates on a turret
able to rotate at 90 degrees in either direction for picking the loads without turning the base
of the forklift. Use in very narrow aisles and employ a rotating mast. Generally electric
powered. Capacity of lifting load is from 1.5- 4 ton.

Fig 2.4: - Turret Trucks Type Forklift

e) ROUGH TERRAIN FORKLIFTS

Rough terrain forklifts are used for outdoor

works where uneven surface conditions
needs to be faced. It is a one type of heavy
capacity forklift widely used for engineering
and construction purposes. It is generally
gasoline, diesel or CNG operated. Load
capacity is 15 ton or more according to size
and operations. Ideal for lumberyards,
construction projects, landscaping and other
outdoor uses.

Fig 2.5: - Rough Terrain Forklifts

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f) HYDRAULIC FORK LIFT OR PALLET TRUCK

Hydraulic forklift is the most compact design from the overall forklift family. It is widely
use in all types of industry where indoor material transportation are essential It is the most
economical solution for small scale industry as well as big ones for transporting loads at
short distances. It is generally hydraulic operated which utilizes the pascal’s principle for
lifting heavy loads at negligible efforts applied. According to the type of hydraulic cylinder
use the forklift can lift the load from 1- 3 ton.

Fig 2.6: - Hydraulic Fork Lift or Pallet Truck

g) SIDE LOADER FORKLIFT

In this type of forklifts, the load lifting pallets are

fitted by the side of the truck, so that while traveling
at long distances operator doesn’t get any kind of
trouble. Use for narrow aisle work where space
between racks is limited. This type of forklifts may
be electric or gasoline powered. Loading or
unloading can be done by the sides. Lifting capacity
are high for this type of forklifts. Fig. 2.7: - Side Loader Forklift

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CHAPTER 3

TWO-WHEEL FORKLIFT MACHINE

3.1 OBJECTIVE

In this project, we investigate a forklift design that is new and different from the existing design.
The new design offers two features:
1. The forklift attached to the frame body end.
2. The other feature is that the new lifting mechanism by using a chain and gear which is
connected to the fork where it is easy to lift and more compact compare to the existing
design.
The remainder of this thesis describes more features and details. And also, we do analysis and
calculation work on the model to make sure it is stable and safe under different working
conditions.

The basic system of a forklift Usually a fully functional forklift would consist of the following
major system.
1. The power system,
2. Driving system,
3. Control system,
4. Loading system

But in our design, we are only concerned with the loading system, since we are not going to
focus on the power, driving, and control system only we will give basic information in the
following two sections the power system will be included in the driving system.

3.2 PROBLEM STATEMENT

A small-scale industry (SAI ENTERPRISES) having major problem related to cost of material
handling system, they do not use automated device so that they use manually machines. The
material handling like lifting of raw materials, transfer the finished product to final stage,
transfer the one product from one department to other department so that overall cost required
for material handling is increase. This cost affected on profit of company so that we avoid this
problem we find solution to overcome above problem with the help of human powered forklift.

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3.3 METHODOLOGY

3.4 DESIGN OF EQUIPMENT AND DRAWING

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Fig 3.1 Diagram of Two-Wheel Forklift Machine

The rear wheels hold the motors and are attached to the frame or casing. The driving motors
are housed below the frame. The frame incorporates a hole for attaching the front wheel, and;
for attaching the fork lifter. D.C. motor is utilized in our project for moving fork, and carrying
objects from one location to another; our project consists of two motors to run the 2 wheels;
whereas the lifting portion is completed by lead screw and it is connected to another motor.
The battery provides power to the motor. The battery is placed at the front platform and a 12-
volt battery is used to provide power.

3.5 SCOPE OF THE PROJECT

The forklift prototype is a four-wheeled that has the ability to follow the direction guided by
the operator. There are four wheels including two driving wheels controlled by two motors
and two free wheels in front that is able to rotate 360°. With four wh eels, both driving wheels

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are always in contact with the surface. This project consists of four main stages, which are
theoretical design, mechanical fabrication, electronic hardware design.

3.6 MARKET SURVEY

A market survey is an important requirement for initiating any successful business. The
objective of a market survey is to collect information on various aspects of the business. This
survey is a tool through which we can minimize risk. After the market survey, the results
must be analysed in order to finalize a business plan.

We are implementing manually guided vehicle, which replaces the normal transporting
methods. So that we want to consider all the sections related to this works such as problems
arising while installing. So, we conducted a market survey by personnel interview techniques
was used with the measure emphasis on personal interview method. Interviews were
conducted through the structure questionnaire, also we go through people who work in large
industries such as production plant, supply station etc.

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CHAPTER 4

WORKING PRINCIPLES

1. The forklift mechanism runs through the Semi-Electric method.

2. In this method, power shifted from one place to another make use of mechanical along with
electrical elements.
3. The project works on the action of rotational motion transfer into linear motion. For this
cause here 12V, 2.5A D.C motors are used.
4. The arrangement of the motor is connected with the wheel shaft. The vehicle is run through
the motor.
5. The motor is attached to the battery. The motor is also connected with the spur gear to
increase the torque and the wheel is directly coupled by the torque in the form of bearing
so the vehicle can run.
6. There is a control unit that controls the motor actions and it has buttons configurations for
different movements.
7. The major causes of the vehicle are no pollution occur.
8. The lead screw is assembled vertically on the guide column and the attachment of the fork
is done with the lead screw. With the help of the motor, the rotational motion of the lead
screw is transforming into linear motion which helps to raise or lower the load.
9. The front line of the platform the forklift positioning is assembled.
10. The safety is the main consideration we took for the design of the forklift, where the forklift
is in the course of loading and the stability of moving system consist point of 3 contacts, 2
rear rotary wheel drives, and in rear one supporting wheel are placed.

4.1 THREE MAJOR PRINCIPLES

In order to operate a forklift, we need to understand three principles which helps in

preventing any kind of accident and for smooth operations.

1. STABILITY TRIANGLE: A lift truck has three points of suspension where the
stability triangle is formed. Unloaded the truck’s center of gravity is generally under
the driver, loaded that center of balance shifts outward towards the edge of the unit’s
triangle.

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2. LOAD CENTER: From the front of the forks on the lift truck to the “center of
gravity” of your load. Remember, if you move your load away from the front face of
the forks, you impact your trucks capacity.

3. CENTER OF GRAVITY: The place where an object will balance on a single point,
not always is this in the middle of an object. Shape of the object can change the
position of the center of gravity. When eying up your load, work to understand where
its center of gravity is, and center that point directly over your forks.

Fig 4.1: - Three Point on Contact Frame

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CHAPTER 5

RESEARCH AND EXPERIMENTAL WORK DONE

5.1 COMPONENTS USED

These are the following components used in forklift: -

1. Motor

2. Gear

3. Battery

4. Mechanical Structure

5. Wheels

6. Lead Screw

7. Bearing

8. DTDC Switch

5.1.1 DC MOTOR

Three 250 RPM dc hub motors are used. They have been selected over normal Dc motors as
they have a better power/weight ratio, greater efficiency and hence are more compact, robust
and reliable. The absence of a commutator and carbon brushes (which are subjected to
mechanical wear and tear due to friction) enables this type of motor to have a longer life. The
armature is the stationary part and has three coils, while the rotor is a permanent magnet. Each
motor has three hall sensors used to detect the position of the rotor. The stator speed Ns and
the rotor speed Nr are both the same at steady state as this is a synchronous motor. The rotor
speed Nr is measured by taking feedback from the hall sensors while the stator speed Ns is the
frequency at which you alternately switch the coils. By taking feedback Nr and Ns are kept the
same.

Hence the speed of the rotor is directly proportional to the frequency of switching and the
output torque is inversely proportional to the frequency of switching.

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Fig 5.1 DC Motor

5.1.2 GEAR

A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh with
another toothed part to transmit torque, in most cases with teeth on the one gear being of
identical shape, and often also with that shape on the other gear.

Two or more gears working in a sequence (train) are called a gear train Geared devices can
change the speed, torque, and direction of a power source. The most common situation is for a
gear to mesh with another gear. The gears in a transmission are analogous to the wheels in a
crossed belt pulley system. An advantage of gears is that the teeth of a gear prevent slippage.
When two gears mesh, and one gear is bigger than the other (even though the size of the teeth
must match), a mechanical advantage is produced, with the rotational speeds and the torques
of the two gears differing in an inverse relationship.

Fig 5.2 Gear

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5.1.3 BATTERY

The battery used in forklift is 12v SMF battery. SMF battery which means Sealed Maintenance
Free battery are sealed completely because there is no need to add water. The electrolyte used
is in the form of gel which fills the cavity of plates. Just like other batteries, it also emits H2
and O2 gases and due to sealed batteries both these gases combine to form water.

SMF batteries measure created in an eco-friendly, ISO Certified & trendy plant with a huge
producing capability and square measure being sold-out worldwide. There are differences
between SMF batteries and other tubular batteries. In SMF Batteries no distilled water or effort
is needed and requires only a.

There is a wide selection of SMF battery on the market to suit all applications of standby power
needs like UPS, electrical converter and Emergency Lights, communication system, hearth
Alarm & Security Systems, Railway communication, electronic group action and money
Registers, star Lanterns and Systems, etc.

The SMF batteries are available industrial plant charged conditions and have a high period
thereby requiring longer time intervals between recharging of batteries available. As we are
one of the leading SMF battery manufacturers, we provide the genuine and products that tops
in six stigmatic tests.

Fig 5.3 Battery

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5.1.4 MECHANICAL STRUCTURE:

The entire structure is made of mild steel. After both the motors are individually connected
to the wheels three rectangular sections are connected between them. They are welded at both
the ends. A rectangular platform is fitted on these sections. A vertical rod is screwed on this
platform with a rectangular rod welded at the top end. The rider stands on the platform and
takes support from the vertical rod. In front side a lead screw is fitted to upper and lower the
load on fork. The lead screw is functional by a motor.

5.1.5 NYLON CASTOR WHEELS:

Two nylon caster wheels are used. The outer diameter of the motor almost matches the rim
size and hence mounting the motor in these wheels is considerably easier. By using a circular
10mm thick plate of mild steel the motor is mounted between the wheels.

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Nylon Castor Wheels can be manufactured by Injection Moulding and also machined from
Solid Bar. The majority of Nylon castors are moulded, with the machined versions typically
used for Extreme Heavy-Duty Applications. Nylon Casters can be manufactured with pure
Nylon material or alternatively can be mixed with glass reinforcing fibres to further increase
their impact resistance for the most demanding of applications. Nylon Castors most commonly
have a hardness range from 80 shore to 90 shore D and a working temperature ran ge between
-30°C and 80°C.

Features & Benefits of Nylon Castors:

• Strong, Durable & Light Weight

• Non Marking

• Wear, Shock & Impact Resistance

• Low Roll resistance on smooth floors

• Temperature Range from -30°C to + 80°C

• Suitable for both Outdoor & Indoor Use

• Resistance to aggressive chemicals & cleaning materials.

Fig 5.5: - Nylon Caster Wheels Fig 5.6: - Supporting Wheel

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5.1.6 LEAD SCREW

Lead screw is attached to the fork and it is used to lift the load on the fork. Lead screw is
attached to the frame by means of bearing.

A leadscrew (or lead screw), also known as a power screw or translation screw, is a screw used
as a linkage in a machine, to translate turning motion into linear motion. Because of the large
area of sliding contact between their male and female members, screw threads have larger
frictional energy losses compared to other linkages. They are not typically used to carry high
power, but more for intermittent use in low power actuator and positioner mechanisms.
Leadscrews are commonly used in linear actuators, machine slides (such as in machine
tools), visas, presses, and jacks. Leadscrews are a common component in electric linear
actuators.

Fig 5.7: - Lead Screw

Leadscrews are manufactured in the same way as other thread forms (they may be rolled, cut,
or ground).

A lead screw is sometimes used with a split nut also called half nut which allows the nut to be
disengaged from the threads and moved axially, independently of the screw's rotation, when
needed (such as in single-point threading on a manual lathe). A split nut can also be used to
compensate for wear by compressing the parts of the nut.

A hydrostatic leadscrew overcomes many of the disadvantages of a normal leadscrew, having

high positional accuracy, very low friction, and very low wear, but requires continuous supply
of high-pressure fluid and high precision manufacture leading to significantly greater cost than
most other linear motion linkages.

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Mechanics

The torque required to lift or lower a load can be calculated by "unwrapping" one revolution
of a thread. This is most easily described for a square or buttress thread as the thread angle is
0 and has no bearing on the calculations.

The unwrapped thread forms a right-angle triangle where the base is long and the height is the
lead (pictured to the right). The force of the load is directed downward, the normal force is
perpendicular to the hypotenuse of the triangle, the frictional force is directed in the opposite
direction of the direction of motion (perpendicular to the normal force or along the hypotenuse),
and an imaginary "effort" force is acting horizontally in the direction opposite the direction of
the frictional force. Using this free-body diagram the torque required to lift or lower a load can
be calculated by using the following equations-

Based on the Tower equation it can be found that the screw is self-locking when the coefficient
of friction is greater than the tangent of the lead angle. An equivalent comparison is when the
friction angle is greater than the lead angle When this is not true the screw will back-drive, or
lower under the weight of the load.

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5.1.7 BEARING

A bearing is a machine element that constrains relative motion to only the desired motion,
and reduces friction between moving parts. The design of the bearing may, for example,
provide for free linear movement of the moving part or for free rotation around a fixed axis;
or, it may prevent a motion by controlling the vectors of normal forces that bear on the moving
parts. Most bearings facilitate the desired motion by minimizing friction. Bearings are
classified broadly according to the type of operation, the motions allowed, or to the directions
of the loads (forces) applied to the parts.

Rotary bearings hold rotating components such as shafts or axles within mechanical systems,
and transfer axial and radial loads from the source of the load to the structure supporting it. The
simplest form of bearing, the plain bearing, consists of a shaft rotating in a hole. Lubrication is
used to reduce friction. In the ball bearing and roller bearing, to reduce sliding friction, rolling
elements such as rollers or balls with a circular cross-section are located between the races or
journals of the bearing assembly. A wide variety of bearing designs exists to allow the demands
of the application to be correctly met for maximum efficiency, reliability, durability and
performance.

Fig 5.8: - Bearing

The term "bearing" is derived from the verb "to bear";[1] a bearing being a machine element
that allows one part to bear (i.e., to support) another. The simplest bearings are bearing
surfaces, cut or formed into a part, with varying degrees of control over the form,

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size, roughness and location of the surface. Other bearings are separate devices installed into a
machine or machine part. The most sophisticated bearings for the most demanding applications
are very precise devices; their manufacture requires some of the highest standards of current
technology.

5.2 PHYSICAL PARAMETERS OF ALL THE COMPONENTS USED

1. Dimension of Base
• Length of Base: 44cm
• Height of Base: 35cm
• Thickness of Base: 3cm
• Height of Bed from Flat Surface: 10cm

2. Dimension Of Sliding Mechanism

• Height of Rails/Channels: 60cm
• Width of Rails: 12cm
• Thickness of slider: 1.3cm
• Size of slider: 13*10cm

3. Motors used
• Type: DC Motor
• Speed: 300 rpm
• Capacity: 12V & 1Amp
• Number Of Motor Used: 3

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CHAPTER 6

DESIGN AND CALCULATIONS

The design of mechanical forklift is derived as follows. Determine maximum load capacity,
lifting height, forces acting on component. The material selected for forklift is Mild Steel due
to its properties like malleability, ductility, strong and low cost.

6.1 DESIGN OF LEAD SCREW –

• Mass carrying (m) = 250 Kg

• Length of screw = 1220 mm

• Factor of safety (FS)= 3

• Material = Mild steel {Syt= 400N/mm 2, E= 210 x 10 3 N/mm2}

1. Total load in Newton –

Total Load (W) = Mass (m) × Acceleration due to gravity (g)

= 250×9.81 = 2450 N

2. Permissible compressive stress (σc)-

σc = Syt/FS = 400/3 =133.33 N/〖mm〗^2

3. Core diameter of screw (dc) –

σc = W/ [π/4×d_c 2] 133.33= 2450/ (π/4×d_c^2) d c= 4.836 mm

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Nominal Diameter d (mm) Pitch, p (mm)

22,24,26,28 5

30,32,36 6

40,44 7

48,50,52 8

Table- 1: Properties of square thread

There are additional stresses due to torsional and bending moments. The diameter should be
increased to account for these stresses. As a square threaded screw with 22 mm nominal
diameter and 5 mm pitch is selected.

We know, d= 22mm, p= 5 mm.

4. Core diameter of screw (dc) –

dc = d – p

= 22 – 5

= 17 mm

5. Mean diameter of screw (dm) –

dm = d – 0.5p

= 22 – 0.5(5) = 19.5 mm

It is assumed that the screw has single start threads.

l = p = 5 mm

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6. Helix angle (α)

tan α = l/ (πd m) = 5/ (π (19.5))

α = 4.666º

7. Friction angle ( ) –

The possible value of the coefficient of friction between screw and nut is 0.35

tan = μ = 0.35

= 19.29º

Since > α the screw is self- locking.

8. Torque required to lift & lower the load –

Mt = (W d m)/2 ×tan( ±α)

For Lifting –

Mt= (2450 × 19.5)/2 × tan (19.29 + 4.666)

Mt= 10613.43 N mm

For lowering –

Mt = (2450 × 19.5)/2 × tan (19.29 - 4.666)

Mt = 6232.91Nmm

9. Check for shear & compressive stress failure –

1. τ = (16M_t)/ (d_c^3) = (16(10613.43))/ (π〖 (17) 〗^3) = 11 N/mm 2

2. σc = W/ [π/4×d_c^2 = 2450/ (π/4 × 17 2) = 10.79 N/mm 2

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11. Checking for buckling failure –

a) Moment of Inertia (I) –

I = π/64 ×d_c^4

= π/64 × 〖 (17) 〗^4

= 4099.82 〖mm〗^4

b) Cross sectional area (A) –

A = π/4 × d_c^2

= π/4 × 〖17〗^2

= 226.98 〖mm〗^2

c) Radius of gyration (K)

K = √(I/A)

= √ (4099.82/226.98)

= 4.249 mm

d) Slenderness ratio (l/K) – l/K=1220/4.249 =287.12.

e) Critical slenderness ratio

End fixity coefficient (n) = 0.25 Syt/2 = (nπ^2 E)/(l/K) ^2 400/2

= (0.25π^2×210×〖10〗^3)/(l/K) ^2

l/K = 50.89

f) Critical load on buckling (Pcr) –

Pcr= Syt [1- Syt/4nπE (l/K) ^2]

Pcr= 400 × 226.98 [1- 400/ (4 ×0.25 × π^2 ×210 ×〖10〗^3) 〖 (50.89) 〗^2]

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Pcr= 45413.15 N.

g) Factor of safety for buckling Failure – FS = Pcr/W

= 45413.15/2450 = 18.53 (So, the design is safe against buckling failure.)

6.2 DESIGN OF NUT –

• Permissible bearing pressure (Sb) = 13 N/〖mm〗^2

• Material = Cast Iron (Sut)= 200 N/〖mm〗^2}

1. No. of threads in contact with screw (Z)

Z = 4W/ (π Sb (d^2- d_c^2))

Z = (4 ×2450)/ (π ×10 (〖22〗^2-〖17〗^2))

Z = 1.23 ~ 2

2. Axial length of Nut (H) –

H = Z× P

H=2×5

H = 10 mm

3. Check for crushing failure of nut (σc)

σc = W/ (π/4 ⌈d^2-d_c^2 ⌉×Z) σc = 2450/ (π/4 ⌈〖22〗^2-〖17〗^2 ⌉×2)

σc = 7.99 N〖mm〗^2

4. Factor of safety for crushing failure

FS = (0.5S_ut)/σc = (0.5 ×200)/7.99 = 12.51

So, design is safe against crushing failure.

6.3 REVOLVING SPEED OF SCREW –

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• Pitch (p) = 5 mm.

• Speed of raise =1Feet/min.

• Raise speed = 1 feet/min = 12 inch/min = 12 × 25.4 mm/min
• Raise speed = 304.8 mm/min
• N = 304.8/Pitch
• N = 304.8/5 = 60 rpm

6.4 SELECTION OF MOTOR –

• Required torque of motor (Mt) = 10613.42 N mm

• Required speed of motor (N) = 60 rpm

• Type of supply to motor = 12 Volt D.C.

Torque required to raise maximum load in Kg-cm = (Mt RAISE)/ (9.81 ×10)
= 10613.42/ (9.81 ×10) = 108.1 kg-cm

Required speed of motor shaft in rpm = 60 rpm.

We have to search market carefully then we find no motor available with this specification so
we choose a motor with 250 rpm 100 Kg-cm torque motor.

Parameter Motor Specifications

Type of motor D.C. Car Window Motor

Speed of motor 300 rpm

Output torque of motor 100 Kgcm

Input voltage and current 12 V 0.7A- at No load

2.5 A- at maximum Load

Table- 2: Specification of motor

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6.5 SELECTION OF GEAR –

The selection of Gears for Power Transmission

Gearbox for Power Transmission –

• Changed Motor torque 〖(Mt)〗_m = 100 Kgcm = 10 × 〖10〗^3 Nmm

• Changed Motor Speed (N)= 100 rpm

• Starting Torque = 150% Rated Torque

• Factor of safety (FS)= 1.5

• Material = Plain Carbon Steel {Sut= 600N/〖mm〗^2}

• Assume Pitch line velocity (v) = 5 m/s

• (b/m) = 10

1. Gear ratio (G) –

We assuming ratio G = 5, & motor speeds = 100 rpm and Torque 100 Kg-cm but with help of
gearing arrangement, we getting of 500 Kg-cm torque & speed 20 rpm.

Gear ratio (G) = Tg/Tp = 5/1

G = 5:1

2. Estimation of Module Based on Beam strength (m) –

2.1 Minimum No. of teeth (z) –

The minimum no. of teeth for 20° pressure angle is 18. Therefore, z_p = 18 z_g
= Gz = 5(18) = 90

The Lewis form factor (Y) is 0.308 for 18 teeth.

2.2 Power Rating (KW) –

KW= (〖(M〗_t)2πN)/ (60 × 〖10〗^6)

KW= 0.104

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2.3 Service factor (C_s)-

C_s= (Starting Torque)/ (Rated Torque)

C_s= 1.5

2.4 Bending stress (σ_b)- σ_b= S_ut/3.

σ_b= 200 N/〖mm〗^2

2.5 Velocity factor (C_v) –

C_v=3/(3+v)

C_v = 0.375.

2.6 Find module (m)

m= [(60 × 〖10〗^6)/π {((KW)C_s (FS))/ (z_p NC_v (b/m) (S_ut/3) Y)}] ^
(1/3)
m= 2.5mm

2.7 Selection of module – For m= 2.5 mm d_p = mz_p = 45mm

dp = mz_p = 225mm b = 10m = 25mm

2.8 Tangential Force (P_t) –

P_t= (2〖(M〗_t))/ (d_p^’)

P_t= 444.44 N

2.9 Pitch Velocity (v)-

v= (πd_p^' N)/ (60× 〖10〗^3) v= 0.235 m/s

2.10 Velocity factor (C_v) –

C_v= 3/(3+v)

C_v= 0.927

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2.11 Effective Load (P_eff)-

P_eff= C_s/C_v ×P_t

P_eff= 719.15 N

2.12 Beam strength (S_b) –

S_b = mbσ_bY

S_b=3850N

2.13 Factor of safety (FS)-

FS = S_b/P_eff

FS = 5.35

Therefore, design is safe. After mounting Gearbox for Power transmission, we have to get
following speed & torque:

Speed (N) = 20 rpm & Torque (Mt) = 500kg-cm

6.6 SELECTION OF BATTERY

From battery available range in market, we assume battery capacity 12V, 7.2 Ah

Required battery capacity = V × I

= 12 × 7.2

= 84.4 Watt

But consider deep cycle of battery is 80% of total capacity of battery

Running capacity of battery = 0.80 × required battery capacity = 70 Watt

We consider following working time –

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Load raise time = 5 min

Load lower time = 5 min

Travel time = 15 min

Total time of one operation cycle = 25 min

So, total time of 25 min battery requires 10 min and in 1 hour we use 3 times battery when
fully charged.

6.7 SELECTION OF BEARING –

• Bearing life = 12000-20000 Hrs

• Radial load (P) = 2450 N

• Speed (n) = 50 rpm

• Assume L_10h = 12000 Hrs

1. Bearing life (L_10) – L_10= (60 × n × L_10h)/〖10〗^6

L_10= (60 ×50×12000)/〖10〗^6

L_10 = 36 million rev.

2. Load capacity (C)

C = P〖(L_10) 〗^ (1/3)

C = 2450〖 (36) 〗^ (1/3)

C = 8089.72 N

Using standard table of bearing selection,

C = 9950 N C_0 = 4150 N d = 12mm, D = 37mm, B = 12mm

But, from available bearing range in market, we are assuming suitable bearing – d = 12mm,

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D = 28mm, B = 8mm
Designation – DGBB 60012 Z

6.8 DESIGN OF FORK –

• Outer face height (D) = 50.8 mm

• Outer face width (B) = 50.8 mm

• Inner ace height (d) = 44.8 mm

• Inner face width (b) = 44.8 mm

• Length of fork (L) = 600 mm

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CHAPTER 7

EQUIPMENT AND OPERATIONS USED FOR FABRICATION

7.1 REQUIRED EQUIPMENTS REQUIRED MACHINE TOOL

1. Welding machine
2. Cutting machine (hacksaw m/c)
3. Hand grinding machine
4. Lathe machine
5. Drilling machine

7.2 REQUIRED TOOLS

1. Spanner set
2. Hammer
3. Rough and smooth file
4. Fasteners
5. Welding electrodes

7.3 REQUIRED MEASURING INSTRUMENTS

1. Measuring tape
2. Right angle
3. Vernier calliper
4. Micro-meter screw gauge

7.4 OPERATION PERFORMED DURING FABRICATIONS

1. Roller machining

2. Roller shaft

3. Roller Box Drilling

4. Bearing Cap Machining

5. Pinion Boring

6. Gearbox shaft machining

7. Rubber wheel shaft

8. Machining

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9. Quarter pin drilling

10. Rib cutting & Base plate cutting

11. Key slots (Rs 25/slot)

12. Motor shaft machining,
13. Surfacing

14. Sheet metal Bending

15. Welding

16. Grinding

17. Cutting

18. Motor wiring & Soldering

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CHAPTER 8

COST ESTIMATION

This cost estimation can vary according to the market availability.

Standard calculation ( all dimension in cm)

1)volume

A) 2 Forks = 2 (l×b×t)

= 2 (82×10.5×0.7)

= 2 ( 602.5 )

= 1205 cm3

Fork also have a side plates at its base. volume of which will be 1200 cm3 . So total volume
of base will be 2400 cm3.

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B) Upper body

The upper body of the forklift have total 4 plates welded together.

a) Front plate = ( L×H×t )

= ( 64×27×0.7 )
= 1200 cm3

b) Upper plate = ( 35×18×0.7)

= 440 cm3

c) 2 side plates = 2 ( 27×18×0.7)

= 340 cm3
Total volume of body above the fork= 1200＋440＋340 = 1980 cm3.

C) Fork lift handle:

I. Long hollow handle = P÷4 (DO 2 _ Di2 ) × L

= p/4 ( 3 2 - 2.32 ) × 90
= 260 cm3

II. Gripping handle = 70 cm3.

Total volume of Whole body and handle= A+B+C

= 2400+2000+250 = 4650 cm3.

2) Weight of body
Mass = Volume × Density Density of mild steel
= 7.8 gm/cm3 Mass
= 4650 × 7.8
= 36270 gm = 36.2 kg

3) Material cost:

Material cost = Mass × Price/ kg

According to our survey market price of the mild steel is 50/kg.
Material cost = 36 × 50 = Rs. 1800

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CHAPTER 9
ADVANTAGES, DISADVANTAGES AND APPLICATIONS
9.1 ADVANTAGES OF FORKLIFT

• Suitable for indoor use.

• Longer life.

• Minimum noise level.

• Eco-friendly operation.

• It can be used in hazardous areas.

• Huge advantage of forklift is that they have no fuel cost.

• The best electric forklift is that they have zero emission which causes safe and
Healthy environment, that is why they can be called the Green Forklift.

• The operation cost is low.

• The life of electric forklift is greater than other types.

• Maintain better control of material management.

• Reduce product damages.

• Reduce manpower.

• Increase productivity.

• Suitable to transfer frames.

DISADVANTAGES OF FORKLIFT
• The speed is low.

• The capability of lifting weight is lower than other forklifts.

• You can’t handle it until you are fully trained.

• They are usable only indoor.

• The main disadvantage is the area should be properly dry and should have controlled.

• Heavy weight goods can’t be lifted from this device.

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• Driver should be careful not to exceed the forklift weight capacity.

APPLICATIONS

• It is also used in small-scale industries.

• It can be used in industries, factories, etc.
• In factories and storage godowns, for storage and transshipment of large goods.
• Movement of light goods weighing 40-60 Kgs, which is cumbersome by human labor.

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CHAPTER 10

RESULTS AND DISCUSSIONS

This project work has been completed in a limited time and hence we are proud to announce
that “The Two-Wheel Drive Forklift” can fulfill the expectations.
All the parts are connected in such a way that the equipment can be maintained and assembled
easily. In this work, we can achieve the target of reduction of the size of a forklift, and hence
the new model can move through narrow passages and lift the load in a storehouse.
We successfully conducted the test of load lifting and we are happy to announce that the forklift
design made by us was able to lift the load of 50Kg additional to the weight of the human
operator under satisfactory conditions.

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CHAPTER 11

CONCLUSIONS AND FUTURE SCOPE

The purpose of this paper was to focus on solving problems at the warehouses using the forklift
to carry a load of lighter weight and making it efficient n reduce the accidents happening in
warehouses due to large forklifts. The two-wheel forklift is designed keeping the center of the
idea to increase work efficiency, reducing power consumption, smaller dimension and hence
aisle for movement in narrow space of warehouses, high safety factor, time-saving application,
easy controlling from onboard

This project has provided us a plethora of opportunities and experiences, within the bounds of
our limited knowledge. Not only did it enlighten us with theoretical knowledge, but it also
inculcated practical knowledge regarding planning, purchasing, assembling, and machining in
us. It is a matter of immense happiness and pride for us in having been able to complete this
project successfully in a limited periodThe size of the forklift can be further reduced for easy
handling and movement the foldable designs can be provided for transporting it in light motor
vehicles.

The development of Mechanical forklift assures the ergonomically comfort to the

operator or worker and to reduces time required for manual lifting and handling. This
increases efficiency of productivity & it provides safety of operator while handling of the
material.

After going through these collected data and statistics from various journals as well as research
papers, we came to conclusion that Two Wheel forklift is the only way to stop such industrial
issues like labor cost, hazardous material handling for s

FUTURE SCOPE

The current system can be made automatic by powering to wheel. And more heavy weight can
be lift using bulky load. The project TWO-WHEEL FORKLIFT can be controlled through
remote control designed. The advantage of using this technology is that it’ll increase the safety
of operator by operating the forklift from certain distance. This will also increase the efficiency
of the productivity, because human errors due to poor visibility can be minimized.

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REFERENCES

• S. S. Rattan, Theory of Machines, 2009.

• V B Bhandari, Design of Machine Elements, 2010.
• J. B. Gupta, Basic Electrical & Electronics Engineering, 2011.
• Brindley, James (December 2005). "The History of the Fork Lift". Warehouse & Logistic
News. Archived from the original on 200
• http://www.mitboston.co.in
• http://en.wikipedia.org/wiki/forklift_truck
• http://link.springer.com
• http://www.researchgate.net
• https://web.archive.org
• http://www.fork-lift-training.co.uk
• http://link.springer.com

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International Journal of Global Research in Science & Technology
ISSN: 2455-3832, Volume No., Issue No, June 2021

DESIGN AND FABRICATION OF TWO-WHEEL FORKLIFT FOR

INDUSTRIAL PURPOSES
Anurag Meena 1, Krishnam Kushwaha 2, Rajesh Janyani3, Rohit Sen4, Ghanshyam Mishra 5
1,2, 3, 4
Student, Department of Mechanical Engineering, Global Institute of Technology,
Jaipur, Rajasthan, India
5
Professor, Department of Mechanical Engineering, Global Institute of Technology,
Jaipur, Rajasthan, India

---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - Forklifts are used to move large and heavy maneuverable forklifts found their integral role in warehouses,
loads, the size is adjustable to adapt to loads of different for lifting the goods to heights. To cater to the needs of the
sizes and to seal warehouse conveyors. The adjustable warehouse sector, suitable modifications were made in the
width allows the conveyor to replace relatively thin design framework of the forklift; a remarkable one being the
passages. A high degree of maneuverability is achieved development of Electric forklifts that were powered by batteries
through the use of steering drive wheels; the lifting of the that required frequent charging. Forklifts can be electric-
load is carried out by the mechanism of self-propelled powered or diesel-powered. Electric forklifts are ideal to be used
mechanical equipment located on both sides of the in areas with lesser ventilation because they are quiet and do not
conveyor. Conveyor operation is controlled by a manual exhaust. Electric forklifts have lower operating costs than
control unit. An elongated vertical element mounted on a diesel-operated ones. However, their lifting capacity is limited
mounting element movably mounted on a truck frame and to 3000 kg. Their batteries can take as long as 16 hours to charge
at least one loading device, the loading device having at least and cool off, and have a slower acceleration than the trucks that
one loading part and two mounting parts, the mounting run on diesel. Diesel-powered forklifts were used outdoors due
part can pass through the corresponding vertical element to the production of exhaust gases. They cost less than electric
Insert into the opening in the centre, and fasten the forklifts to buy, but they have higher ongoing costs, as they need
elements such as pins or bolts passing through the frequent refueling. It is capable of lifting weights in the range of
alignment holes through the vertical members and the 1000-25000 Kg’s, which makes them ideal for heavy-industry
fastening parts to fix the fastening elements in place, and situations and under in all types of weather.
the fasteners are spaced between the corresponding vertical
elements. This can also be achieved by a combination of 2. LITERATURE REVIEW
fork tips. Each fork tip has a loading port and a fastening
2.1 Burinskiene: “The Travelling of Forklift in
part, which can be inserted into the upper or lower end of
Warehouse”. Retrieved 2008-01-22.
the opening of various vertical supports, or a tool extender,
After conducting an intensive literature review, it wasfound that
the loading part of which is suitable. The container
Extreme pressure is placed on all functions of a traditional
interacts, its fastening material can be inserted into the
warehouse. The warehouses have to be flexible and can increase
upper open end of the vertical element and activate a 180-
or decrease their operations to meet any demand. This has both
degree movement.
advantages and challenges. A key advantage is that warehouses
Keywords: Forklift forks., life, machine, weights. are ready to underlay economic trends and seasonality. A key
challenge is that they have to stay competitive in today’s market.
This means that managers and engineers must continue to
1. INTRODUCTION improve the performance of their warehouse operations.

A forklift or a lift truck (also known as counterbalanced 2.2 Brindley, James (December 2005). "The History of the
truck) is a powered industrial vehicle, a truck to be specific, Fork Lift".
which enables the lifting, shifting, and movement of materials \Warehouse & Logistic News. Archived from the original on
from one place to another in an industry. Its primary applications 2009-08-31. Retrieved 2008-01-25. In 1906, the Pennsylvania
are in warehouses, shops, and construction sites, wherein it is Railroad introduced battery-powered platform trucks for
used for the transshipment of goods. The earliest forklift truck moving luggage at their Altoona, Pennsylvania train station.
was invented between 1914 and 1915 and put on the market in World War I saw the development of different types of material
the 1930s. The widespread usage of forklifts started in the period handling equipment in the United Kingdom.
of World War II as a result of the surge in the demand for
transporting military materials. After World War II,

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ISSN: 2455-3832, Volume No., Issue No, June 2021

2.3 Dr. R. N. Mall (2013), Automated Guided Vehicle, ISBN

2091 Journal, MMMEC, Gorakhpur.
In the market there are several types of forklifts are used in
warehouses. These forklifts are either powered by gasoline,
propane, or electricity but they are more difficult to maintain and
fuel can be costly which takes more space. To overcome this
entire problem, we designed and fabricate the wheel forklift
which drives on electric power, and loading & unloading is done
by a hydraulic jack through forks.

3. OBJECTIVE

In this project, we investigate a forklift design that is new and

different from the existing design. The new design offers two
features:
1. The forklift attached to the frame body end.
2. The other feature is that the new lifting mechanism by
using a chain and gear which is connected to the fork where it
is easy to lift and more compact compare to the existing
design.
The remainder of this thesis describes more features and
details. And also, we do analysis and calculation work on the
model to make sure it is stable and safe under different working
conditions.

The basic system of a forklift Usually a fully functional forklift

would consist of the following major system.
1. The power system,
2. Driving system,
3. Control system,
4. Loading system
The rear wheels hold the motors and are attached to the frame
or casing. The driving motors are housed below the frame. The
But in our design, we are only concerned with the loading
system, since we are not going to focus on the power, driving, frame incorporates a hole for attaching the front wheel, and; for
attaching the fork lifter. D.C. motor is utilized in our project for
and control system only we will give basic information in the
following two sections the power system will be included in the moving fork, and carrying objects from one location to another;
driving system. our project consists of two motors to run the 2 wheels; whereas
the lifting portion is completed by lead screw and it is
4. METHODOLOGY connected to another motor. The battery provides power to the
motor. The battery is placed at the front platform and a 12-volt
A forklift; is known as a self-generated vehicle, and maybe a battery is used to provide power.
battery-powered industrial machine; in which purpose is for
A. Components used
material handling among compounds, especially the potential
to raise weights to be positioned at a certain height, also to The components used in the project Two Wheel Drive Fork
lowers them as per needs. These are connected with specific Lift is as follows:
attachments, the fork elevated machine is also made to perform • DC Motor
alternative connected functions like the transfer masses from
slip sheets onto pallets, also to clamp them or to invert them.
The chassis was designed to sustain a static load of 80 kg

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ISSN: 2455-3832, Volume No., Issue No, June 2021

• Battery motion. For this cause here 12V, 2.5A D.C motors are used.
The arrangement of the motor is connected with the wheel
shaft. The vehicle is run through the motor. The motor is
attached to the battery. The motor is also connected with the
spur gear to increase the torque and the wheel is directly
coupled by the torque in the form of bearing so the vehicle can
run. There is a control unit that controls the motor actions. The
major causes of the vehicle are no pollution occur. The lead
• Bearing screw is assembled vertically on the guide column and the
attachment of the fork is done with the lead screw. With the
help of the motor, the rotational motion of the lead screw is
transforming into linear motion. The front line of the platform
the forklift positioning is assembled. The safety is the main
consideration we took for the design of the forklift, where the
forklift is in the course of loading and the stability of moving
system consist point of 3 contacts, 2 rear rotary wheel drives,
and in front 2 supporting wheel are placed.
• Spur gear and chain
6. DESIGN OF EQUIPMENT AND DRAWING

• Lead Screw

• Wheels

5. WORKING PRINCIPLE

The forklift mechanism runs through the Semi-Electric method.

In this method, power shifted from one place to another make
CAD DESIGN OF THE MODEL
use of mechanical along with electrical elements. The project
works on the action of rotational motion transfer into linear

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7. PHYSICAL PARAMETERS OF THE • Ease of lifting the loaded light vehicles.

COMPONENTS USED • Ease of handling.
• Ease of replacement of any parts.
1. Dimension of Base • A clean, green, eco-friendly machine.
Length of base: 30cm
Width of base: 25 cm B. Disadvantages
The thickness of base: 3 cm • Time consumption is high.
Height of bed from the flat surface: 10 cm • The initial cost is high.

2. Dimension of sliding mechanism

C. Applications
Forklift Beam Height: 40 cm
• It is also used in small-scale industries.
Forklift Max Reach: 30cm
• It can be used in industries, factories, etc.
Fork Length: 7 cm
• In factories and storage godowns, for storage and
Fork Width: 4 cm
transshipment of large goods.
3. Motors used • Movement of light goods weighing 40-60 Kgs, which
Type: DC Motor is cumbersome by human labor.
Capacity: 12v & 1 Amp
No. of Motor Used: 3 A Two Wheel Drive Forklift is used for this purpose as it is
fast, efficient, ha s lesser power consumption, and requires
8. COST ESTIMATION ANALYSIS lesser space for its movement.

Sr. Part/Product Qty. Cost 10. RESULTS AND DISCUSSIONS

No This project work has been completed in a limited time and
hence we are proud to announce that “The Two-Wheel Drive
1. Structure 4 2000
Forklift” can fulfill the expectations.
2. Motor 3 1500 All the parts are connected in such a way that the equipment
can be maintained and assembled easily. In this work, we can
3. Wheel 4 2000
achieve the target of reduction of the size of a forklift, and
4. Nut & bolt 20 100 hence the new model can move through narrow passages and
lift the load in a storehouse.
5. Bearing 6 500
We successfully conducted the test of load lifting and we are
6. Battery 1 1500 happy to announce that the forklift design made by us was
able to lift the load of 80Kg under satisfactory conditions.
7. Lead screw 1 1000
8. Chain and 2 200 11. CONCLUSIONS AND FUTURE SCOPE
sprocket The purpose of this paper was to focus on solving problems at
9. Joystick 1 200 the warehouses using the forklift to carry a load of lighter
weight and making it efficient n reduce the accidents happening
10. Miscellaneous 1000 in warehouses due to large forklifts. The two-wheel forklift is
11. Total 10000 designed keeping the center of the idea to increase work
INR efficiency, reducing power consumption, smaller dimension
approx. and hence aisle for movement in narrow space of warehouses,
high safety factor, time-saving application, easy controlling
from onboard
9. ADVANTAGES, DISADVANTAGES, AND
APPLICATIONS This project has provided us a plethora of opportunities and
experiences, within the bounds of our limited knowledge. Not
A. Advantages only did it enlighten us with theoretical knowledge, but it also
• Ease of maintenance (including checking and inculcated practical knowledge regarding planning,
purchasing, assembling, and machining in us. It is a matter of
cleaning).
immense happiness and pride for us in having been able to
• Easy for repairing.
complete this project successfully in a limited period. We have

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ISSN: 2455-3832, Volume No., Issue No, June 2021

done everything in the best possible way we could by

overcoming the various constraints and by utilizing all the
available amenities. The current system can be modified for
lifting heavy loads by using a bulky lead screw and a high-
power motor. The size of the forklift can be further reduced for
easy handling and movement the foldable designs can be
provided for transporting it in light motor vehicles.

REFERENCES

[1 ] S. S. Rattan, Theory of Machines, 2009.

[2 ] V B Bhandari, Design of Machine Elements, 2010.
[3 ] J. B. Gupta, Basic Electrical & Electronics Engineering,
2011.
[4 ] Brindley, James (December 2005). "The History of the
Fork Lift". Warehouse & Logistic News. Archived from
the original on 200.

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